Amine-modified thermoplastic phenolaldehyde resins, and method of making same



AMINE-MODIFIED THERMOPLASTIC PHENGL- ALDEHVDE RESINS, AND METHOD OF MAK- ING SAME Melvin De Groote, St. Louis, Mo., assignor to Petrolite Corporation, Wilmington, DeL, a corporation of Eelaware No Drawing. Original application September 23, 1953,

Serial No. 381,980. Divided and this application December 6, 1956, Serial No. 626,612

8 Claims. (Cl. 260-53) This application is a division of my copending application Serial No. 381,980, filed September 23, 1953.

Attention is directed to my co-pending applications, Serial Numbers 288,742, through 288,746, inclusive, filed May 19, 1952, all now abandoned. The first of said copending applications relates to synthetic condensation products obtained by condensing certain phenol-aldehyde resins, therein described in detail, with certain basic nonhydroxylated secondary monoamines, also therein de- The present application is differentiated from the aforementioned five applications in that the aldehyde used, instead of being formaldehyde, is furfural. Stated another way, this invention is concerned with certain heatstable oxyalkylation-susceptible resinous condensation products obtained by condensing certain phenol-aldehyde resins, hereinafter described in detail, with certain basic secondary amines, also hereinafter described in detail, and furfural.

For purpose of illustration itmay be simpler to divert momentarily to the products described in the five aforementioned co-pending applications, Serial Nos. 288,742 through and including 288,746, inclusive, and for sake of simplicity to the first one, i. e., Serial No. 288,742, in which the amine reactant is a non-hydroxylated monoamine. For purpose of simplicity the invention described in said co-pending application, Serial No. 288,742, may be exemplified by an idealized formula, as follows:

R R R in which R represents a hydrocarbon substituent generally having 4 and not over 18 carbon atoms but most preferably not over 14 carbon atoms, and It generally is a small Whole number varying from 1 to 4. In the resin structure it is shown as being derived from formaldehyde R! in which R represents any appropriate hydrocarbon radical, such as an alkyl, alicyclic, arylalkyl radical, etc.,

r 2,828,284 Patented Mar. 25,1958

free from hydroxyl radicals. The only limitation is that the radical should not be a negative radical, which considerably reduces the basicity of the amine, such as an aryl radical or an acyl radical. Needless to say, the two occurrences of R may jointly represent a single divalent radical instead of two monovalent radicals. This is illus trated by morpholine and piperidine. The introduction of two such amino radicals into a comparatively small resin molecule, for instance, one having 3 to 6 phenolic nuclei as specified, alters the resultant product in a number of ways. In the first place, a basic nitrogen atom, of

course, adds a hydrophile effect; in the second place, de-v pending on the size of the radical R, there may be a counterbalancing hydrophobe effect or one in which the hydrophobe effect more than counterbalances the hydrophile effect of the nitrogen atom. Finally, in such cases where R contains one or more oxygen atoms, another effect is introduced, particularly another hydrophile efiect. I

Such condensates, i. e., the condensates of Serial No. 288,742, and in fact the instant condensates, are obtained from phenol-aldehyde resins. It is well known that one can readily purchase on the open market, or prepare, fusi ble, organic solvent-soluble, water-insoluble resin polymers of a composition approximated in an idealized form by the formula R R n R In the above formula 11 represents a small whole number varying from 1 to 6, 7 or 8, or more, up to probably 10 or 12 units, particularly when the resin is subjected to heating under a vacuum as described in the literature. A limited sub-genus is in the instance of low molecular weight polymers where the total number of phenol nuclei varies from 3 to 6, i. e., it varies from 1 to 4; R represents a hydrocarbon substituent, generally an alkyl radical having from 4 to 14 carbon atoms, such as a butyl, amyl, hexyl, decyl or dodecyl radical. Where the divalent bridge radical is shown as being derived from formaldehyde it may, of course, be derived from any other reactive aldehyde having 8 carbon atoms or less.

When in the preparation of certain phenol-aldehyde resins formaldehyde is replaced by furfural precautions must be taken if one is attempting to obtain an organic solvent-soluble resin. The reason is that cross-linking is produced due to the unsaturation of furfural in addition to its usual functionality as an aldehyde. This has been stated briefly as follows:

Other aldehydes than formaldehyde react readily with phenol, but these resins arenot commercially important except the reaction product of phenol with furfural. The condensation products are much darker in color than the resins from formaldehyde. The resins are formed by the condensation of furfural with phenol in alkaline solution. The condensates cure on heating to 350 F. with evolution of heat. This polymerization is believed to be of the vinyl type, involving the double bonds in the furane ring HO OH formaldehyde has-been used along with furaldehyde in some instances. (See Synthetic Resins and Rubbers, Powers, John Wiley & Sons, Inc., New York, 1943, page 78) p Thus, it becomes apparent thatthe oversimplification which 'hasbeen previously presented in connection with formaldehyde in the following manner:

must be rewritten in connection with furfural in the following manner:

Revertin g 'again to' what is said in the' five co-pending applications previously referred to, and particularly" to Serial No. 2 8 8,7 42, reference is made to the text which describes other products of reaction which appear in the co generic' mixtur'e resulting from reaction between the resin,"the "'secondary amine and formaldehyde. The reference is asf ollows'z In conducting reactions of this kind one does not necessarily obtain a hundred percent yield for obvious reasons. Certain side reactions may take place. For instance, 2 moles of amine may combine with one mole of the aldehyde, or only one mole of the amine may combine with the resin molecule, or even to a very slight 4,. For reasons which are obvious from an examination of the literature concerned with the production of furane resins, and particularly resins in which furfural is involved, no attempt has been made to show how any two or more of the same four'constituents can dimerize or trimerize. The four constituents in mind are the three that have been noted in the preceding text as to presence in the cogeneric mixture and, more specifically, theprimary reactant which has been described previously, thus:

It is quite possible that in the presence of an alkaline catalyst as distinguished from an acid catalyst, polymerization does not go beyond a dimer or a trimer. The types, of course, would be indicated as AA, BB, CC, DD, AB, AC, AD, BC, BD, etc. It is quite possible that at least some trimers are formed. In any event, to the extent that there is present in a reaction mass involving formaldehyde certain products which may be considered by products it becomes obvious that these same types, of resultants, i. e., the by product type of resultant, becomespart of'a larger molecule when furfural is used. Thus, it is quitepossible that practically all the resultants of reaction involve the original amine and the origithick,'viscous, tacky liquid, and shows a higher molecular weight by various procedures employed, although such methods are not necessarily completely satisfactory from an analytical standpoint; and (b) the products obtained frcm furfural can be'heated at temperatures higher than those herein described inthe preparation of the-products, and will not infrequently convert into an insoluble resin. At least in mostinstances the addition of more furfural with subsequentheating so converts them. Comparable c'ndens .tes derived from formaldehyde do not convert ver in the presence of additional forma dehyde. Furthermore, the composition of the instant products are complicated by the fact that furfural as such mightpolymerize to a dimer prior to reaction and thus involve a different type of compound tha'n'in some mentioned previously. In any. event, the condensates so obtained are different in chiracter and for some purposes particularly after oxyalkylation with ethylene oxide, propylene oxide, bu-

tyleneoxide, glycide, or methylglycide are particularly effective for the resolution of petroleum emulsions. Indeed, in many instances the oxyalkylation derivatives are distinctly moreeifective than the comparable products derived from condensates'in which formaldehyde is used.

For purpose of convenience What is said hereinafter I will be divided into five parts:

for the-resolution of petroleum emulsions; and

35 extent, 1f at all, 2 resin units may combine without any amine in the reaction product, as-indicated in the following formulas;

R;\ H /Rr NC-N H R] R1 0 OH OH H C 0 CN H L R t.

a t 0H 0H 0H o H H H H r H coOo-Oo c an H H H H H R n R R p 7 When formaldehyde is replaced by furfural the three previous formulas become as follows: 0

Ri\ H /Ri"' N-CN\ R R H 'oH 0H R H I H v H H 1% 65 R n R (B) OH OH OH OH OH H H l H H H H H H H R R n" R n R R purposes other than demulsification, and particularly for their use as initial raw materials which are subjected to oxyalkylation.

PART 1 This part is concerned with the preparation of phenolaldehyde resins of the kind described in detail in U. S. Patent No. 2,499,370, dated March 7, 1950, to De Groote and Keiser, with the following qualifications; said aforementioned patent is limited to resins obtained from difunctional phenols having 4 to 12 carbon atoms in the substituent hydrocarbon radical. For the present purpose the substituent may have as many as 18 carbon atoms, as in the case of resins prepared from tetradecylphenol, substantially para-tetradecylphenol, commercially available. Similarly, resins can be prepared from hexadecylphenol or octadecylphenol. This feature will be referred to subsequently.

In addition to U. S. Patent No. 2,499,370, reference is made also to the following U. S. patents: Nos. 2,499,365, 2,499,366, and 2,499,367, all dated March 7, 1950, to De Groote and Keiser. These patents, along with the other two previously mentioned patents, describe phenolic resins of the kind herein employed as initial materials.

For practical purposes, the resins having 4 to 12 carbon atoms are most satisfactory, with the additional C carbon atoms also being very satisfactory. The increased cost of the C and C carbon atom phenol renders these raw materials of less importance, at least at the present time.

Patent 2,499,370 describes in detail methods of preparing resins useful as intermediates for preparing the products of the present application, and reference is made to that patent for such detailed description and to Examples 1a through 103a of that patent for examples of suitable resins.

As previously noted, the hydrocarbon substituent in the phenol may have as many as 18 carbon atoms, as illustrated by tetradecylphenol, hexadecylphenol and octadecylphenol, reference in each instance being to the difunctional phenol, such as the orthoor para-substituted phenol or a mixture of the same. Such resins are described also in issued patents, for instance, U. S. Patent No. 2,499,365, dated March 7, 1950, to De Groote and Keiser, such as Example 71a.

Reference has been made to an earlier formula which was in essence an over-simplification representing a phenol-formaldehyde resin. Actually, some other aldehyde, such as acetaldehyde, propionaldehyde, or butyraldehyde, may be used. The resin unit can be exemplified thus:

in which R" is the divalent radical obtained from the particular aldehyde employed to form the resin.

As previously stated, the preparation of resins of the kind herein employed as reactants is well known. See U. S. Patent No. 2,499,368, dated March 7, 1950, to De Groote and Kaiser. Resins can be made using an acid catalyst or basic catalyst or a catalyst showing neither acid nor basic properties in the ordinary sense, or without any catalyst at all. It is preferablethat the resins emloyed be substantially neutral. In other words, if prepared by using a strong acid as a catalyst, such strong acid should be neutralized. Similar, if a strong base is used as a catalyst, such strong acid should be neutralized. Similarly, if a strong base is used as a catalyst it is preferable that the base be neutralized although we have found that sometimes the reaction described proceeded more rapidly in the presence of a small amount of free base. The amount may be as small as a 200th of a percent and as much as a few l00ths ofa percent. Sometimes moderate increase in caustic soda and caustic pot- 6 ash may be used.. However, the most desirable procedure in practically every case is to have the resin neutral.

In preparing resins one does not get a single polymer, i. e., one having just 3 units, or just 4 units, or just 5 units, or just 6 units, etc. It is usually a mixture; for

instance, one approximating 4 phenolic nuclei will have some trimer and pentamer present. Thus, the molecular weight may be such that it corresponds to a fractional value for n as, for example, 3.5, 4.5 or 5.2.

In the actual manufacture of the resins I found no reason for using other than those which are lowest in price and most readily available commercially. For purpose of convenience suitable resins are characterized in the following table:

TABLE I M01. Wt

Ex- Po ition R of resin ample R or R derived n molecule number ir0in- (based on n+2) 1a Phenyl Perm... 3.5 992.5

20 Tertiary butyl ...d0 3.5 882.5

Secondary butyl.- Orth0. 3.5 882.5

Oyelohexyl Para... 3.5 1025.5

Tertiary amyl do 3.5 959.5

Mixed secondary Orth0... 3.5 805.5

and tertiary amyl.

Pro Para... 3. 5 805. 5

Oct 3.5 1.1905

Tertiary butyl .do. 3. 5 945. 5

Tertiary amyl .do, 3.5 1 022.5

Nonyl .do. 3. 5 1. 330. 5

Tertiary butyl 3. 5 1, 071. 5

Tertiary amyl d0 3. 5 1.148. 5

Nony "do ....'d0. 3.5 1456.5

Tertiary butyl. mpional- 3. 5 1,008.5

dehyde.

Tertiary amyl d 3. 5 1.085. 5

ony 3.5 1,393.5

Tertiary buty 4. 2 996. 6

Tertiary amyl do 4. 2 1, 083. 4

Tertiary butyl- 4.8 1, 094.4

Tertiary amyL. 4. 8 1, 189. 6

Nonyl 4. s 1, 570. 4

PART 2 i As noted previously, a variety of secondary amines free from a primary amino group may be employed. These amines fall into five categories, as indicated previously.

One category consists of strongly basic secondary mon oamines free from hydroxyl groups whose composition may be indicated thus:

R! in which R represents a monovalent alkyl, alicyclic, arylalkyl radical and may be heterocyclic in a few instances as in the case of piperidine and a secondary amine derived from furfurylamine by methylation or ethylation, or a similar procedure.

Another example of a heterocyclic amine is, of course, morpholine.

The secondary amines most readily available are, of course, amines such as dimethylamine, methylethylamine,

. cleus.

diethylamine, dipropylamine,.ethylpropylamine, dibutylamine, diamylamine, "dihexyla mine, 'dioctylamine, and dinonylannne; Other amines include Ibis.( 1, 3 dim ethyl'- butyDamine'. There are, o f course, a variety of primary amines which can be reacted .with an alkylating agent such as dirnethyl sulfate, diethyl sulfate, an alkyl bromide, an ester of sulfonic acid, etc., to produce suitable amines within the herein specified limitationsQfFor example, one an' h l s .a h mst ylbe ai m ne or benzylamine itself, to produce a suitable reactann'; Needless ,to say, one can'use secondary amines sdch as die clohexylamine, dibutylamine oramines containing one y oh yl oup a d we ky m p, nci nzy group and one alkyl group, such as ethylcycl ohekylamine, ethylbenzylamine, etc. 7

-. Other suitable compounds are exemplifiedrby Other somewhat similar secondary amines are those of the composition R- (CH2)a as described in U. S. Patent No. 2,375,659, dated May 8, '1945, to Jones et al. In the above formula R may be methyl, ethyl, propyl, amyl, octyl, etc.

Other amines can be obtained from products which are sold in the open market, 'such as may be obtained by alkylation of cyclohexylmethylamine or the alkylation of similar primary amines, or, for that matter, amines of the kind described in U. S. Patent No. 2,482,546, dated September 20, 1949, to Kaszuba, provided there is no negative group or halogen attached to the phenolic nu- Examples include the followings: beta-phenoxyethylamine, gamma-phenoxypropylamine, beta-phenoxyalpha-methylethylamine, and betaphenoxypropylamine.

Other suitable amines are the kind described in British Patent No. 456,517 and may be illustrated by The secondary category represents secondary amines which are hydroxylated monoamines. These may be illustrated by diethanolamine, methylethanolamine, dipropanolamine, dibutanolarnine and ethylpropanolamine.

Suitable primary amines which can be so converted into secondary amines include butylamine, amylamine, hexylamine, higher molecular weight amines derived from fatty acids, cyclohexylamine, benzylamine, furfurylamine, etc.

Other suitable amines include Z-amino-l-butanol, 2-

amino 2 methyl 1 propano l, 2 amino 2' -'methyl- 1 1,3-propanediol, 2-amino-2-ethyl 1,3 propanediol, and

tris-(hydroxylmethyl) aminoethane. Another example of such amines is illustrated by 4-arnino-4-methyl- 2- pentanol.

Other suitable compounds are the following:

(CzHsO CzHsO C2H4) HO C2134 (CzHaO CzH4O CzHs C2114) NH 1 HOCQEU/ (0.11.0 cmcmonn 0 (CH3) oncm) NH HOCaH4 (CHzOCHzCHzOCHaCHzO onion an VHQQHK/I (CHsOCHECHQCHzGHZCHzCHi) HOCzH4 or comparable compounds having two hydroxylated groups 'ofdifierent lengths as in (-HOCHQCHgOCHZCHzOCHZCHz) HOC2H4 7 Other examples of suitable amines include alphamethylbenz ylamine and monoethanolamine; also amines obtained by treating cycloheaylmethylamine with one mole of an oxyalkylating agent as previously described; beta ethylhexyl butanolamine, diglycerylamine, etc. Another type of amine which isof particular interest because it includes a very definite hydrophile group includes sugar amines suchas glucam-i-ne, glactamine and fructamine, such as N-hydroxyethylglucamine, N-hydroxyethylgalactamine, and N-hydroxyethylfructamine.

Other suitable amines may be illustrated by t 7 HO-CHz-(II-CHzOH IIIH HO-CHMIJ-CHOH CH: r CHa-(3-CH2OH 7 11m CHs-CtCHaOH See, also, corresponding hydroxylated amines which can be obtained from rosin or similar raw materials and de, scribed in U, S. Patent No. 2,510,063, dated June 6, 1950, to Bried. Still other examples are illustrated by treatment of certain secondary amines, such as the following, with a mole of an oxyalkylating agent as described; phenoxyethylamine, phenoaypropylamine, phenoxyalphamethylethylamine, and phenoxypropylamine.

Polyamines free from a hydroxyl group may be illustrated by the following:

CzHs

CzHs C2 5 The fourth category consists of polyamines having hydroxylated groups which may be characterized by the following:

ozrnon HO O2H4 C2H4O CzHrN 110cm. oinion 02KB /C 2 5 N CzHAO C2H4N CrHtOH O H s Npropylene propyleneN H O C2H4 CzHtOH HO C2H4 CZEAOH HO C2114 C2 40H HOC2H4 02114013.

CH: CH:

Suitable cyclic amidines which may or may not have a hydroxyl group but are free from primary amino groups may be illustrated by the following:

A compound having no basic secondary amino radical but a basic primary amino radical can be reacted with a mole of an alkylene oxide, such as ethylene oxide, propylene oxide glycide, etc., to yield a perfectly satisfactory reactant for the hereindescribed condensation procedure. This can be illustrated in the following manner by a compound such as N- CH: C11HasC JaHA-NH,

2 heptadecyl,1 aminoethylimidazoline which can be reacted with a single mole of ethylene oxide, for example, to produce the hydroxy ethyl derivative of Z-heptadecyl,

. l6 l-aminoethylimidazoline, which can be illustrated by the following formula:

Other reactant may be employed in connection with an initial reactant of the kind described above, to wit, 2- heptadecyl,l-aminoethylimidazoline; for instance, reaction with an'alkylene imine such as ethylene imine, propylene imine, etc. If reacted with ethylene imine the net result is to convert a primary amino radical into a secondary amino radical and also to introduce a new primary amine group. If ethylene imine is employed, the net result is simply to convert Z-heptadecyl, l-aminoethylimidazoline into Z-heptadecyl, l-diethylenediaminoimidazoline- However, if propylene imine is used the net result is a compound which can be considered as being derived hypothetically from a mixed polyalkylene amine, i. e., one having both ethylene groups and a propylene group between nitrogen atoms.

PART 3 The products obtained by the herein described processes represent cogeneric mixtures which are the result of a condensation reaction or reactions. Since the resin molecule cannot be defined satisfactorily by formula, although it may be so illustrated in an idealized simplification, it is difficult to actually depict the final product of the cogeneric mixture except in terms of the process itself.

The herein described amine-modified resins are obtained from furfural and not formaldehyde. Due to the greater reactivity of furfural for reasons previously ex-' plained as far as I am aware one cannot substitute furfural for formaldehyde in the manufacture ofresins of the phenol-amine-aldehyde type. Generally speaking, the objective in the preparation of these amine-modified resins is to obtain a heat-convertible compound even by using formaldehyde. It is not necessary to point out the complications involved when furfural is used. See, for example, U. S. Patent No. 2,031,557 to Bruson. ince the condensation products obtained are not heat-convertible and since a temperature up to C. or thereabouts may be employed, it is obvious that the procedure becomes comparatively simple. Indeed, perhaps no description is necessary over and above what has been said previously, in light of subsequent examples. However, for purpose of clarity the following details are included.

A convenient piece of equipmentv for preparation of these cogeneric mixtures is a resin pot of the kind described in aforementioned U. S. Patent No. 2,499,368. In most instances the resin selected is not apt to be a fusible liquid at the early or low temperature stage of reaction if employed as subsequently described; in fact, usually it is apt to be a solid at distinctly higher temperatures, for instance, ordinary room temperature. Thus, I have found it convenient to use a solvent and particularly one which can be removed readily at a comparatively moderate temperature, for instance, at 150 C. A suitable solvent is usually benzene, xylene, or a comparable petroleum hydrocarbon or a mixture of such or similar solvents. Indeed, resins which are not soluble except in oxygenated solvents or mixtures containing such solvents are not here included as raw materials. The reaction can be conducted in such a way that the initial reaction, and perhaps the bulk of the reaction, takes place in a polyphase system. However, if desirable, one can use an oxygenated solvent such as a low-boiling alcohol, including ethyl alcohol, methyl alcohol, etc. Higher alcohols can be used or one can use a comparatively non-volatile solvent such as dioxane or the diethylll other of ethylene glycol. One can also usea mixture of benzene or xylene and such oxygenated solvents.- Note that the use of such oxygenated solvent is not required in the sense that it is notnecessary to use an initial resin which is soluble only in an oxygenated solvent as noted, and it is not necessary to have a single phase system for reaction.

In many instances furfural itself has a solvent effect and thus presents less difficulty from the standpoint of reaction containing a formaldehyde which not only is a poor solvent but also usually is used in aqueous form. Furfural, of course, is substantially anhydrous. .Of course water is formed in the condensation reaction. If the solvent is completely removed at the end of the process, noproblemis involved if the material is used for any subsequent reaction. However, if the reaction mass is going to be subjected to some further reaction where the solvent may be objectionable as in the case of ethyl or hexyl alcohol, and if there is to be subsequent oxyalkylation, then, obviously, the alcohols should not be used or else it should be removed. The fact that an oxygenated solvent need not be employed, of course, is an advantage for reasons stated. 7 Another factor, as far as-the selection of solvent goes, is whether or not the cogeneric mixture'obtained at the end of the reaction is to be used as such or in the salt form. The cogeneric mixtures obtained are apt to be solids or thick viscous liquids in which there is some change from the initial resin itself, particularly if some of the initial solvent is apt to remain 'without'complete removal. Even if one starts with a resin which is almost water-white in color, the products obtained are almost invariably a black or black-red in color. Indeed, the mere use of furfural itself seems to produce at least a type of material that gives the product a darker color and, indeed, considerably darker than comparable products derived from formaldehyde.

By and large, the melting point is apt -to belower'and theproducts may be more sticky and more tacky than the original resin itself. Depending on the resin selected and on the amine selected the condensation product or reaction mass on a solvent-free basis may be hard, resinous and comparable to the resin itself.

" The products obtained, depending on the reactants selected,,may be water-insoluble, or water-dispersible, or water-soluble, or close to being water-soluble. 'Water solubility is'e'nhanc'ed, of course, by making a solution in the acidified vehicle such as a dilute solution, for instance, a'5% solution of hydrochloric acid, acetic acid, hydroxyacetic acid, etc. One also may convert the finished product into. salts by simply adding a stoichiometric amount of anyselected acid and removing any water present by refluxing with benzene or'the like. In fact, the selection of the solvent employed may depend in part whether or not the product at the completion of the reaction is to be converted into a salt form.

In the next succeeding paragraph it is pointed out that frequently it is convenient to eliminate all solvent, using 'a temperature of not over 150 C. 'iandemployingvacuum-if required. This applies, of course," only toifthose circumstances where it is desirable or necessary to remove the solvent. Petroleum solvents, aromatic solvents, etc., can be used. The selection of solvent; such as benzene, xylene or the like, depends primarily on cost, i. e., the use of the most economical solvent and also,on three other factors, two of which have been mentioned previously; (a) is the solvent 'to'rernain'in'the reaction mass without removal? (b) is the reaction mass, to be subjected to further reaction in which the solvent, for instance, an alcohol, either low boiling or "highboiling, might interfere as in the case of oxyalkylation? and the third factor is this (0) is an effort to be made to purify the reaction mass by the usual procedure as,for example, a waterwash to remove any unreacted low molal soluble amine, if employed and present after reaction? 1 Such procedures are well known and, needless to say,"certain solvents are more suitable than others. Everything else being equal, I have found xylene the most satisfactory solvent.

I have found no advantage in using a low temperature, approximately room temperature, at the start of the reaction although this is sometimes done purely as a matter of convenience. Indeed, using furfural I have usually done nothing more than prepare the reaction mixture, add a suitable amount of xylene, and reflux for approximately 3 to 6 /2 hours at temperatures varying, as the case may be, from 135 to 160 C. Where the amine has a comparatively low basicity I have sometimes added a small amount or approximately 1% of sodium methylate.

However, using a xylene-benzene mixture, for instance, approximately 170 parts of benzene and 35 parts of xylene, and a phase-separating trap to eliminate water, I have found that I could employ temperatures between and C., and eliminate the water of condensation by refluxing at this temperature. However, I have found no particular advantage in using this low temperature over and above the high temperature previously noted.

Example 1b The resin employed was the one previously designated as 28a and had a molecular weight of approximately 600. 175 grams of this resin were dissolved in an equal weight of xylene and 61 grams of di-isopropanolamine added. 58 grams of furfural were added and the mixture stirred for about 30 minutes and then the temperature allowed to rise to C where it was allowed to reflux for 6 hours. During this refluxing period a phase-separating trap was used to remove the water of formation. At the end of this time the reaction was complete and the product was obtained in the form of a xylene solution. A small sample was evaporated to eliminate the xylene. The resultant product was a highly viscous, tacky material, being black in color with areddish tinge.

Similar products were prepared as indicated in the following table.

TABLE II Solvent Max. Resin (xylene Time temp. Ex. N o. amt., Secondary amine Amt., Furfural, unless period, during grams grams amt. otherwise his. reaction,

' n t d), 0. grams 175 Di-iso ropylamine 61 p 58 175 6 140 Di-n-htylamine- 65 48 150 4 150 150 Di-ethylamino. 37 48 150 4 140 1,50 Di-cyclohexylamule 91 48 --l5[) 6 160 300 Morpholine 87 96 300 5. 5 150 300' D i-2ethylhexylamine 241 '96 300 3. 5 160 225 Bis-(1,3-d imethylbutyDamiue. 139 72 225 225 D i-isopropanolamine 100 7 225 2 150 225 a-Methylbenzylethanolamine 124 72 225 2. 5

. 225 Di-ethanolamine 79 72 225 1. 75 100 225 Aminoethyl ethanolam 78 72 225 1.5 130 225 Diethanolamine 79 72- 05-170 2 93 225 do 79 72 "55-170 2 95 TABLE II-Contiriued Solvent Max.

Resin (xylene Time temp. Ex. No. amt., Secondary amine Amt, Furfural, unless period, during grams grams amt. otherwise hrs. reaction,

noted), T0.

grams 225 Di-lsopropanolamine 174 128 225 1. 33 125 236 Di-isopropylarnine 61 58 236 6 140 197 Dl-n-butylamine 65 48 197 4 150 197 Di-ethylamine 37 48 197 4 140 197 Di-cyclohexylarnine- 91 48 197 6 160 393 Morpholine 87 96 393 5. 150 393 Di(2-ethylhexyl)amine 241 96 393 3. 5 160 197 N-rnethylauiline 54 48 197 3 160 295 Di-(beta-phonylethyl)am 169 72 295 3. 5 155 295 Di-lsopropanolamine 100 72 295 2 150 225 Diethanolamine 79 72 295 1. 75 150 188 Di isopropylamine 61 58 225 6 140 188 Di-n-butylamine- 65 48 188 4 150 188 Di-ethylamine 37 48 188 4 140 374 Di-cyclohexylamine 91 48 188 6 160 374 Mor holine 87 96 374 6.6 150 188 Di-(2ethylhexyl)amine 241 96 374 3. 5 160 280 N-rnethylaniline 54 48 188 3 160 280 Di-(beta-phenylethyDamine. 169 72 280 3.5 155 280 Didsopropanolatnlne 100 72 280 2 150 280 Dl-ethauolamine 79 72 280 1. 75 150 NOTE.--:I1l the above examples no catalyst was added. In some duplications of the above small amounts of catalyst were added up to 1% to 2% of either powdered caustic soda or powdered sodium methylate. No advantage was noted in the use of a catalyst provided the amine was suincleutly basic.

In Examples 12b, 13b and 14!; indicated by the double asterisk the solvent was a. mixture of 170 parts of benzene and 05 parts of xylene.

'lhe molal ratio of resin to amine to aldehyde was 1 to 2 to 2, except in Examples 141) and 1.57) where the ratio was 1 to 3.5 to 3.5 111 both instances.

In Exarnples 1'!) through 15b the resin employed was the one identified as Example 28a. In Examples 16?) through 20?) the resin employed was the one identified as Example 32a, and in Examples 267) through 35b the resin employed was identified as Example 39a.

PART 4 As to the use of conventional demulsifying agents reference is made to U. S. Patent No. 2,626,929, dated January 7, 1953, to De Groote, and particularly to Part 3. Everything that appears therein applies with equal force and efiect to the instant process, noting only that where reference is made to Example 13b in said text beginning in column 15 and ending in column 18, reference should be to Example 8b, herein described.

PART 5 products which are not only valuable for the purpose dcscribed in regard to the parent material or the salts of the parent material, but also for other purposes. Likewise, since the tertiary amino nitrogen atom is present the products can readily be reacted with suitable reactants such as chloroacetic acid esters, benzylchloride, alkyl halides, esters of sulfonic acids, methylsulfate, or the like, to give quaternary ammonium compounds which are used, not only for the purposes herein described, but also for various other uses.

In such instances where the amine contains a hydroxyl group the product is susceptible to reactions involving the hydroxyl radical, particularly acylation reactions, etc., i. e., reactions involving the use of either monocarboxy acids which may be low rnolal or high molal, and polycarboxy.

acids of the kind previously enumerated.

The products herein described as such and prepared in accordance with this invention can be used as emulsifying agents, for oils. fats and waxes. as ingredients in insecticides compositions, or as detergents and wetting agents in the laundering, scouring, dyeing, tanning and mordanting industries. They also may be used for preparing boring or metal-cutting oils and cattle dips, as metal pickling inhibitors, and for pharmaceutical purposes.

Other uses include the preparation or resolution of potroleum emulsions, whether of the water-in-oil type or oilin-water type. They may be used as additives in conncction with other emulsifying agents; they may be employed to contribute hydrotropic effects; they may be used as anti-strippers in connection with asphalts. They may be used to prevent corrosion, particularly the corrosion of ferrous metals for various purposes and particularly in connection with the production of oil and gas, and also in refineries where crude oil is converted into various commercial products. The products may be used industrially to inhibit or stop microorganic growth or other objectionable lower forms of life, such as the growth of algae, or the like; they may be used to inhibit the growth of bacteria, molds, etc.; they are valuable additives to lubricating oils, both those derived from petroleum and synthetic lubricating oils, and also to hydraulic brake fluids of the aqueous or nonaqueous type. Some have definite anticorrosive action. They may be used in connection with other processes where they are injected into an oil or gas well for the purpose of removing a mud sheath, increasing the ultimate flow of fluid from the surrounding strata, and particularly in the secondary recovery operations using aqueous flood waters. They may be used also in dry cleaners soaps.

With regard to the above statements, reference is made particularly to the use of the materials as such, or in the form of a salt; the salt form refers to a salt involving either one or both basic nitrogen atoms. Obviously, the salt form involves a modification in which'the hydrophile character can either be increased-or decreased and, inverscly, the hydrophobe character can be decreased or increased. For example, neutralizing the product with practically any low rnolal acid, such as acetic acid, hy droxy acetic acid, lactic acid, or nitric acid, is apt to markedly increase the hydrophilc effect. One may also use acids of the type and petroleum acids such as naphthenic acids and acids;

obtained by the oxidation of wax. One can also obtain- The hydrophile efiect may be aeaaesa 1-5 new products having unique properties by combination with polybasic acids, such as diglycolic acid, oxalic acid, dirnerized acids from linseed oil, etc. The most common examples, of course, are the higherfat-ty acids having generally 10 to 18 carbon atoms. I hav e found that a particularly valuable anti-corrosive Fagent can be obtained from any suitable resin and formaldehyde provided the secondary amine is hydroxyethyl cyclohexylamine. The corrosion inhibiting properties'o'f this compound can be increased by neutralization with either one or two moles of an oil-sulfonic acid, particularly a sulfonic acid of t e type known as mahogany sulfonicacid.

I have found the products herein described are-of unusual utility for preventing the separation of sludge in fuel oil during storage. c

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

l. The process of condensing (a) an oxyalkylation-susceptible, fusible, non-oxygenated organic solvent-soluble, water-insoluble, low-stage phenol-aldehyde resin'having an average molecular weight correspondingfto atileast 3 and not over 6 phenolic nuclei 'per resin molecule; said resin being derived by reaction between a difunctional monohydric phenol and an aldehyde having notover 8 carbon atoms and reactive toward said phenol; saidresin being formed in the substantial absence of phenols of functionality greater than 2; said phenol being of the formula in which R is an aliphatic hydrocarbon radical having at least 4 and not more than 24 carbon atoms and substituted in the 2,4,6 position; (b) a basic secondaryamine free from any primary amino radical and having notm'ore than 32 carbon atoms in any group attached to-any amino nitrogen radical and reactive towards furfural; and(c) furfural; said condensation reaction being conducted at a temperature sufiiciently high to eliminate Water'and'below the pyrolytic' point of the reactants and resultants 'of retion; and withthe proviso that the resinous condensation product resulting from the process be heat-stable and oxyalkylationsusceptible. i

2. The process of claim 1 with the proviso that-there be an alkanol radicatattach'ed to at least one amino nitrogen atom.

3. The process of condensing (a) anbxyalliylationsusceptible, fusible, non-oxygenated organic -solvent soluble, water-insoluble, low-stage phenol-aldehyde'r esin having an average molecular weight corresponding to at least 3 and not over '6 phenolic nuclei per resin nioleculeysaid resin being derived by reaction between a difunctional monohydric phenol and-an aldehyde having not over 8 carbon atoms and reactive toward'saidphenol; said resin being formed in the substantial absence of phenols'of functionality greater than 2; said phenol being of the formula irfiwhich R is" an aliphatic hydrocarbon radical having at least 4 and notmore than 24rcarbon,atomsandsub stituted in the 2,1 4, 6 po'sition; (a)' a basic hydroxylated secondary monoaniinefhaving not more than 32 carbon atoms in any groupatta'ched to the' amino nitrogen and reactive towards"ft'irfural;--and ('c)ifurf.ural; said condensation' reaction 'being conducted' at a temjperaturesufficiently'h igh'to eli inate water and below the pyrolytic point of thereact'ants andresu'l'tants of reaction; Withthe proviso that'the condensation reaction be conducted so as p the ratio of reactants be approximately 1, 2 and 2*respectively; and with the final proviso that the resinous condensation product resulting from the process be heat- 7 stable and oxyalkyla'tion snsceptible. V

4. The process of condensing (a) an oxyalkylati onsusceptible, fusible, non-oxygenated organic solvent-soluble, water-insoluble, low-stage phenol-aldehyde resin having an averagemolecularweight corresponding to at least I 3 and not over 6 phenolic nuclei per resin molecule; said resin being derived by reaction between, a difunctional monohydric PhfillQlfiIldflll aldehyde having notioveri 8 carbon atoms and reactive'towa'rdsaidtphenol; said resin being formedfin VtheslibstantiaI absence of phenolslof functionality greater-than 2; said phenol vbeing of the formula t in which'k is an aliphatic hydrocarbon radical having at least 4 and notmore thani24 carbon atoms and sub: stituted in the 2,4, 6fpositior'1; (b) a basic hydroxylated secondary monoamine having not more than 32 carbon atoms in any group attached to the'ar'nino nitrogen atom and reactive towards furfural; and (c) furfur'al; said condensation reactionbeing conducted at a'temperatu're sufficiently high to eliminate water and below the pyrolytic point of -the reactants and 'resultants of reaction; with the proviso that the condensation reaction be'conducted so as to produce a significant portion of the resultant in which each of the three reactants have contributed part of the ultimate'molecule by virtue of a furfurabderived substituted methylene bridge connecting the amino nitrogen atom with a resin molecule; with the added proviso that the ratio of reactants by approximately 1, 2 and 2, respectively, with the further proviso that said procedure involve the use of a 'solvent; and' with the-final proviso that the resinous condensation product resulting from the process be heat-stable and oxyalkylation-susceptible.

5. The process of condensing (a) an toxyethylationsusceptible, fusible, non-oxygenated organic solvent-soluble, Water-insoluble, low-stage phenol-formaldehyde resin having an average molecular weight corresponding to at least 3 and not over 6 phenolic nuclei per resin-molecule; said resin being derived by reaction between'a difunctional monohydric 'phenoland formaldehyde; said resin being formed in the substantial absence of; phenols of functionality greater than 2; said phenol being of the formula 1 in which R is an aliphatic hydrocarbon radical having at least 4 and not'rnore thant24 carbon atoms and substituted in the 2, 4, 6 position; (b) a basic hydroxylated secondary monoarnine having not more than 32 carbon atoms in any group attached to the aminotnitrogen' atom and. reactiye tow'ards furfural; and ('c) furfural; said condensation reaction being; conducted at a temperature suf ficiently' high to eliminate water and below the pyro'lytic point 'of the reactants and resultants of reaction; with the proviso thattthe condensation reaction be 'conducted so as to produce a significant portion of the resultant in which .each of the three reactants have contributed part bf the ultimate molecule byvirtue" ofa furfural-deriv'ed substitutedmethylene bridge connecting the amino nitroaeaeasa soluble, water-insoluble, low-stage phenol-formaldehyde I resin having an average molecular weight corresponding to at least 3 and not over 5 phenolic nuclei per resin. molecule; said resin being derived by reaction between a ditunctional monohydric phenol and formaldehyde; said resin being formed in the substantial absence of phenols of functionality greater than 2; said phenol .being of the formula in which R is an aliphatic hydrocarbon radical having at least 4 and not more than 14 carbon atoms and substituted in the 2,4,6 position; (b) a basic hydroxylated secondary monoamine having not more than 32 carbon atoms in any group attached to the amino nitrogen atom and reactive towards furfural; and (c) furfural; said condensation reaction being conducted at a temperature above the boiling point of Water and below 150 C., with the proviso that the condensation reaction be conducted so as to produce a significant portion of the resultant in which each of the three reactants have contributed part of the ultimate molecule by virtue of a furfural-derived substituted methylene bridge connecting the amino nitrogen atom with a resin molecule; with the added proviso that the ratio of reactants be approximately 1, 2 and 2, respectively; with the further proviso that said procedure involve the use of a solvent; and with the final proviso that the resinous condensation product resulting from the process be heat-stable and oxyalkylation-susceptible.

7. The product resulting from the manufacturing process defined in claim 1.

=8. The product resulting from the manufacturing process defined in claim 6.

'No references cited. 

1. THE PROCESS OF CONDENSING (A) AN OXYALKYLATION-SUSCEPTIBLE, FUSIBLE, NON-OXYGENATED ORGANIC SOLVENT-SOLUBLE, WATER-INSOLUBLE, LOW-STAGE PHENOL-ALDEHYDE RESIN HAVING AN AVERAGE MOLECULAR WEIGHT CORRESPONDING TO AT LEAST 3 AND NOT OVER 6 PHENOLIC NUCLEI PER RESIN MOLECULE; SAID RESIN BEING DERIVED BY REACTION BETWEEN A DIFUCTIONAL MONOHYDRIC PHENOL AND AN ALDEHYDE HAVING NOT OVER 8 CARBON ATOMS AND REACTIVE TOWARD SAID PHENOL; SAID RESIN BEING FORMED IN THE SUBSTANTIAL ABSENCE OF PHENOLS OF FUNCTIONALITY GREATER THAN 2; SAID PHENOL BEING OF THE FORMULA 